Method of making layers of distended fibrous materials



F. L.. BRYANT 1,841,785

S MATERIALS Jan. 19, 1932.

METHOD OF MAKING LAYERS OF DISTENDED FIBROU 3y sheets-sheet 1 Filed June 19, 1930 F. L. BRYANT 1,841,785

METHOD OF MAKINGl LAYERS OF DISTENDED FIBROUS MATERIALS Jan. 19, 1932.

Filed June 19. 1930 3 Sheets-Sheet 2 METHOD` OF MAKING LAYERS OF DISTENDED FIBROUS MATERIALS Filed June 19, 1930 3 Sheets-Sheet 3 Patented Jan. '19, 1932'- `UNI'I'ED sTATEsPATENT OFFICE FRANK L. BBYANT,`OF CHICAGO, ILLINOIS, ASSIGNOR, BY MESNE ASSIGNMENTS, T CELLUFOAM CORPORATION, OF CHICAGO, ILLINOIS, A CORPORATION 0F `DELAWARE METHOD OF MAKING LAYERS DISTEN DED FIBROUS MATERIALS v.Application led June 19,

' '10 lulose fibres, which are impregnated with a bubble forming or foam forming ingredient which when agitated causes the fibrous mass to distend by the formation of minute bubbles throughout the mass, so that its volume becomes Greatly augmented, with the result that when fed forward in the form of a layer and dried under conditions which prevent it from being crushed down or compressed, it assumes the form of a light iiuiiy la er adapted V to subserve numerous purposes or which a material of this character having absorptive properties is iitted, and is also adapted in coarser form for use as a packing 'for furniture or fragile articles. The product of the present 4method possesses the above characteristics, but in addition thereto, vand as a result of the special operations embodied in the present invention, 4the layer is provided on one s'ide with a somewhat tough, coherent and paper-like skin, which is formed out of the mass of material itself during the process of its manufacture, and which serves to better maintain the layer in the form of a coherent body of substantially V`'uniform thickness, thereby better ada ting it for use asa packing or padding of t e character commonly employed in the makingofpads for stair carpeting, although the material is adapted for numerous uses in which the cushioning orprotective eifect is desired. v A

The texture of the layer can be .modified in considerable degree by a preliminarybeating which may constitute-one of the steps of the present method, and which lbeating serves to shorten or break down the fibres to the l'desired extent, depending, however, upon the purpose for which the layer is intended. The beating period will also vary with re- 5 gard to the constituents of the stock 'employed -movements with respectto the tank or con- 1930. lserial 1516.462318.'

action. In general, it may be said that for v most purposes a beating action of about an hour is desirable, which produces a mass which when subjected to the treatment hereinafter described will emerge in the form of a layer having a somewhat cellular texture, but with the fibres of sufficient length to aiord the necessary cohesion and resistance to crushing pressure. In short, the product will have a certain resiliency which enables it-to serve as a pad where a cushioning or like effect is desired. l

Vhere the preliminary beating is continued for several hours, the libres become so shortened that in the ultimate product the texture will be rather of a spongy or cellular character butwithout a great deal of resiliency, although for some purposes a product of t e last mentioned character may be desirable. i

lV here theproduct is not subjected to the preliminary beating, the bres will be long, and there will be little of the cellular or spongy quality in the product, which for most purposes is considered tobe a desirable characteristic. l

It isv of the utmost vimportance that after the preliminary beating the mass of fibrous material, which may be cellulose or the like, or cellulose incombination with other luify or iibrous material, suchas hair, 'be thoroughly impregnated with. the bubble forming ingredients and distended, while in semiliquid form, and subjected to agitation by 1agitating blades designed' to give to the mass a swift vertical movement having a centrifugal component and a downwardly directed component, and of so directing these tainer within which the mass is held that there will also be imparted to the mass. a' surging in and out movement which more l fully'tends to impregnate the fibre forming ingredients and to cause the necessary frothing and distension, and this agitating process is continued until the mass assumes a creamy consistency and becomes distended to two or three times its original volume, at which time the mass is in condition to permit it to be discharged from the agitating receptacle in the form of a thick sheet or layer, which as discharged is preferably of quite substantial depth or thickness. Suitable results are obtained by the discharge of a layer of from one inch to an inch and half in thickness, although, 0f course, the thickness of the layer will depend in considerable measure on the purpose for which the layer is intended and the degree to which it has been distended by the bubble forming or foam forming ingredients contained in the mixture.

After the material has been thoroughly agitated, it is discharged onto the moving foraminous bed of a F ourdrinier machine, which carries the material forward in the form of a continuous layer of uniform thickness, and in order to create upon the under surface of the layer asomewhat tough coherent skin of paper-like consistency, the layer, immediately after it is discharged upon the bed of the F ourdrinier machine, is subjected momentarily to a vacuum, preferably above five inches, whichrhas the effect of suddenly exhausting most of the moisture from the under surface of the mass, contiguous to the vacuum box, without, however, imparting the suction deeply into the mass, so that the under surface only will be thus subjected to the compacting influence of the somewhat heavy suction, which results in the formation on the under surface of a skin layer, without, however, subjecting the remainder of the mass to any substantial deree of com ressive action so that above they skin layer the mass will retain its fluffy or spongy consistency, which gives to it the cushioning properties which the layer of the present invention is primarily intended to retain.

After the layer of material has traveled beyond what may be termed the heavy suction, it is thereafter subjected to a lesser vacuum of about three inches, which serves to abstract a large portion of the moisture, without, however, breaking down or compacting the fibrous body of the layer, so that as it is discharged from the Fourdrinier machine it will display the characteristics of a fibrous or spongy pad, with a paper-like surface skin of considerable toughness. In

this condition the layer is fed onwardly Without compressive contact and without being subjected to disrupting or disturbing influences, into an elongated drying chamber, through which it passes and Within which it becomes thoroughly dry, so that at the point of discharge from thev drying chamber it may be cut into sections of the desired dimensions and stored or packed for shipment.

If it is desired to prevent staining of the surfaces by the evaporation of the chemicals employed to expand the mass, the layer, during itsprogress throughthe drying chamber, may be brought intov surface contact upon its upper and lower surfaces with thin sheets of absorptive material, such as paper or fabric, which serve by contact and capillary action to draw the liquid chemicals from the surfaces of the layer and effect the ultimate evaporation of the liquid constituents upon the surfaces of the protective strips, rather than the surfaces of the layer of material itself, thus preventing staining of the material; and the present process includes this protective step in the drying operation,

Valthough where the material is used for packing or padding, and Where a slight surface discoloration is unobjectionable, this step in 'the process may be omitted.

Throughout the entire progress of the layer of-distended material, from its discharge from the agitating receptacle until its final delivery at the far end ofthe drying chamber, the layer will be adequately supported in an undisturbed condition vand without subjection to the pressure of rolls or the like which are commonly employed in the paper making' industry, since save for the momen- J tary subjection of the layer to a relatively lsectional views of successive portions of one and the same machine designed to continuo uslly produce the layers of distended materia Fig. 4 is an enlarged sectional elevation through the drying chamber;

Fi 5 is a section through one of the suction oxes;

Fig. 6 is a plan view of the beater;

Fig. 7 is a side elevation of the beater;

Fig. S is an enlarged'plan view of the bed block of the beater;

Fig. 9 is a longitudinal section through the bed block;

Fig. lOvis an end elevation of the beater roll; and

Fig. 11 is a perspective view of a small section of the material, showing by heavy line the paperlike skin on the under surface thereof.

The mass of cellulose or other fibrous ma-.-

journalled at its inner end within a journal mounting 25, and at its outer end within a journal mounting 26, and adjacent to the mounting 26 is a pulley 27 upon the beater roll shaft 28, which pulley mounts a belt 29 adapted to impart rotation to the roll.

As illustrated in Fig. 7, the roller turns in an anti-clockwise direction, and the flow of the material follows the arrowsas indicated in Fig. 6. Theroll is provided with teeth or serrations 30 extending from end to end of the roll, and having a slight forward proj ection toward the direction of rotation. Below the roll is located an adjustable bed block 31, which as shown in Fig. 8 is provided on its surface with obliquely arranged inset metallic strips 31L which coact with the teeth of the roll in disintegrating the fibres and reducing them to the desired length. The bed block 31 contacts a rubber diaphragm 32 to which it is clamped by an outer plate 33, and the diaphragm bridges across a gap or orifice 34 in the flooi' of the beater tank so as to prevent the escape of liquids and at the same time permit the bed block to be vertically adjusted to bring it to the desilelvd distance from the surface of the beater ro In order to impart an upward or lifting pressure to the bed block against the tension of the diaphragm 32, the bed block is provided with ears 35 between which is pivoted the upwardly extending end 36 of a lever 37 which is fulcrumed between ears 38 and provided on its end with a depending rod 39 adapted to receive weight disks v40 in the number requisite to impart the desired lift- -ing effect to the bed block.

The floor of the beater tank, at a point beyond the beater roll as regards the direction of travel of the matenal, is provided with a curved plate 41 which stands in spaced relation to the surface of the roll and a'ords a narrow or restricted channel through which the material is forced upwardly and caused to overflow when subjected to the impulsion yof the beater roll, and in order to prevent an -outiow of the liquid, a

curved provided above 'the roll.

` With the beater in operation, the. mixture of fibrous material and water will be subjected to the agitating and disintegrating aetion of the roll in coaction with the bed block, so that a swift current will be mainshield is.l

tained around the circuit of the tank and the fibres reduced to the desired length and degree of ineness, which will depend upon the length of time the material is subjected to the beating action and upon the speed of the roll and the adjustment of the bed block. For most purposes, a beating of. approximately an hour will reduce. the fibrous material to the desired condition of fineness, after which it is. necessary to incorporate,

with the liquid mixture a suitablequantitj7 of bubble forming or foam foaming ingredients of the general character set forth and described in Patent No. 1,7 40,280, of December 17, 1929. It may also at this stage he desirable to incorporate with the mass ar quantity of hair or other fibrous material which it is desired to introduce into the com1')leted` layer. Experience has shown that the incorporation into the mass of an amount of hair equal in Weight to fifty percent of the cellulose or other fibrousmaterial contained in .the liquid mixture will produce a highly desirable product, although it will be understood that the introduction of such materials as hair or the like is optional. When introduced they serve to strengthen and improve Athe cushioning properties of the resulting product, and to produce a product which may successfully compete with pads or the like composed entirely of hair or similar materials.

After the bubble-forming ingredients have been added to the liquid mass, with or Without the addition of hair or the like, the mass is poured into a tank 43 within which the material is agitated and distended by the action of propeller blades 444-44 mounted upon a vertical shaft 45, which is driven from a motor 46 or othersource of power.

The shaft 45 is preferably located off center with respect to the tank 43, which is preferably circular, so that as the material is driven outwardly by the action of the propeller blades it will sweep around the wall of the tank and be alternately directed 1nwardly toward the propeller blades and outwardy and away therefrom during lts circuit around the tank. While the tank, as shown, is of cylindrical or circular formation, similar results may be obtained by the use of a barrel-shaped tank o'r one otherwise configured. The blades of the propeller are preferably formed with downwardly` turned tips 47,p

combined downward and outward `thrust to vthe material, which gives the-vertical motion,

and which, combined with the surging action caused by. the eccentric relation to the blades to the tank, serves to thoroughly agitate the material without any tendency to-additionally break up the minute fibres. The construction and arrangement of the blades themselves are fully set forth and described in co-pending application Serial No. 452,901, filed May 16, 1930.

After the material has been thus agitated for a sufficient period to cause it to distend through the action of the bubble-forming or foam-forming ingredients, to about two and a half times its original liquid volume, and

after the hair or other material, if any, has

roller 5l and a rear power driven roller 52.

Immediately in advance of the power driven roller, the belt o r carrier passes downwardly over a supporting roller 53, and the lower turn of the belt or carrier passes over a rear roller 54, a forward guide roller 55, and under a tension-roller:56.

Near the forward end of the Fourdriniermachine is located whatl may be termed a heavy suction box 57 connected by a suction pipe 58 with a suitable source 0f vacuum adapted to maintain a relatively heavy vacuum of approXimately live inches in the heavysuction box, the purpose of which is to momentarily subject the layer of material,

immediately after its delivery onto the bed of the Fourdrinier machine, to a sufficiently heavy suction to draw down and compact the under surface of the layer of material, thereby causing the libres to cohere and compact together in the formation of a tough paperlike under skin.

Near the rear end of the Fourdrinier machine are located a series of relatively light suction boxes 59 connected by pipes 60 with a suitable source of vacuum 61 adapted to maintain a light suction of approximately three inches of vacuum in the suction boxes, which is a much less degree of vacuum than is commonly employed in the paper making art, and less than the vacuum in the vacuum box 57, the light vacuum boxes being relied upon to withdraw moisture, without, however, additionally compacting the body of the layer of material.

In order to give proper definition to -the width of the layer, gauge belts 61a of rubber or suitable composition are employed, one on each side of the bed or carrier, and these beds are properly'held and supported to rest upon and travel with` the carrier and constitute side walls or flanges for gauging the depth of the layer of material and for affordinf a sharp or clean cut edge to the la er.

n order to insure a proper depth o material, which should ordinarily be flush with the lower turns of the gauge belts, a scraper bar 62 is provided immediately to the rear of the spout 48, which serves to level down the layer to the level of the gauge belts, after which the layer is not again subjected to any compressive or deformative action save and except the suction previously described.

The gauge belts are mountedl upon ooved rollers 63 at the forward and rear en s thereof, and the upper turn of each belt is supported by an intermediate roller 64 which allows the lower turn of each belt to rest bodily upon the moving carrier of the Fourdrinier machine and to travel therewith by friction without the necessity of providing means for positively feeding the gauge belts.

The layer of material A passes from the traveling conveyor of the Fourdrinier machine over a stationary shoe 65 and onto the surface of an endless carrier belt 66, the upper turn of which lies flush with the surfaces of the carrier 49 and the shoe 65. The carrier belt 66 is carried upon supporting rollers 67 and passes under a forward roller 68 suitably spaced to distend the forward end of the belt and thereby cause the lower turn to move upwardly in oblique relation to the forward i roller 67. as indicated in Fig. 2. The carrier belt 66 passes a rear power driven roller 69, and the upper and lower turns in proximity to the powerv driven roller are supported on guide rollers 70 and 71, respectively. The upper and lower turns of the endless carrier 66 both pass through an elongated dr ing chamber 72 of boxhke formation, which as shown vis supplied with heated air throu h forward, intermediate and rear ports 73, 74 and 7 5, respectively. The first port is located near the forward end of the drving chamber while the last occupies a position near the discharge end thereof.

Each of the ports, as shown in Fig. 4, is in duplicate, and discharges from each side into the'drying chamber at a level with the carrier therein, so that the hot air will be discharged above and below the layer of material being dried, and the duplicate ports in each instance communicate with side ducts 76 which pass upwardly around opposite sides of the drying chamber and receive heated air from an air delivery duct 77. Similar delivery ducts 78 and 79'deliver the heated air to vlo , adhering ber it will stand a higher drying temperature than is desirable at subsequent vstages in its progression toward the point of delivery.I The air is withdrawn from the bottom of the drying chamber through return ducts 80, 81 and 82, which communicate with an exhaust fan not shown, for the purpose of maintaining a circuit iiow of heated air through the drying chamber. j

Where it is desired to contact the upper and/or lower surfaces ofthe layer of material with an absorbent sheet or strip, in order to prevent discoloration of the surface in drying, the yfollowing mechanism is provided: i

A lower strip 83vof absorbent paper or the like and a similar upper strip 84 are fed over rolls 85 and 86 in position to contact respectively the lower and upper surfaces of the layer of material during its progress through the drying chamber. As shown, the

strip 83 is wound up on a roll 87, and the upper strip 84 is wound up on a roll 88, although other arrangements for feeding one or moreV absorbent strips of the' character mentioned might be employed in lieu of the arrangement shown.

The foregoing mechanism serves by way of exempliication to illustrate the process of the present invention, but it will be understood that the process can be otherwise carried out on mechanisms of different descriptions without departing from the spirit of the invention. The arrangement shown, however, is one which permits a continuous and undisturbed feeding of lthe material from the agitating tank to the point of nal delivery, and after the layer has once begun to travel along the bed of the Fourdrinier machine, the process can lbe continued uninterruptedly for an indefinite period of time until the supply of material in the agitating tank has been exhausted. The product produced by the method of the present invention is one which possesses a relatively thick, cushionlike resilient body, which is protected and held against disintegration by the formation, on one of its surfaces, of a thin relatively tough and coherent skin formed from the same body fibres and removal, which skin surface is highly desirable, in that it 'tends to conserve the form of the layer as a whole and protects the layer against abrasion, so that it may be more readily used as pads for stair carpeting, or elsewhere.

Although for most purposes the formation of a single surface skin is adequate to afford the desired protection, nevertheless, it is within the contemplation of the present invention, if desired, to Vduplicate the suction to produce a similar on'tle upper surface of the layer, which may be desirable where additional protection against abrasion thereto suiciently to prevent easy methods for expanding the fibrous material, 'slnce the present invention relates in the main to the method of treating fibrous material distended by any suitable method, in

such a way as to produce a layer havin thereon a skin formed by the compacting o the surface bres.

. I claim: A,

1. The method of producing a layer of disten-ded fibrous material, which consists in incorporating into the material a substance adapted to produce foaming when subjected to agitation, agitating the material to produce a distension thereof by the formation of minute bubbles throughout the mass, discharging the material in the form of a thick fluffy layer, and subjecting the surface of the layer to suction in sufficient degree and dring a. period of time adequate to compact the fibrous ingredients of the surface subjected to suction to produce a paperlike skin hereon without compacting the body of the ayer. 2. The method of producing a layer of distended'fibrous material, which consists in incorporating into the material a substance adapted to produce foaming when subjected to agitation, agitating the material to produce a distension thereof by the formation of minute bubbles throughout the mass, discharging the material in the form of a thick iiuify layer, and subjecting the surface of the layer to suction in sufficient degree and during a period of time adequate to compact the fibrous ingredients of the surface subjected to suction to produce a paperlike skin thereon without compacting` the body of the layer, and thereafter subjecting the layer to j drying operation without compacting the distended body of the layer. v

3. The method of producing a layer of distended fibrous material, which consists in inlayer to suction in suiiicient degree and dur# ing a period of time adequate to compact the fibrous ingredients of the surface subjected to suction to produce a paperlike skin thereon without compacting the body of the layer,

and thereafter subjecting the layer to a lesser degree of suction to extract moisture without compacting the body of the layer.

4. The method of producing a layer of distended fibrous material, which consists in incorporating into the material a substance adapted to produce foaming when subjected to agitation, agitatin the material to produce a distension thereo by the formation of minute bubbles throughout the mass, discharging the material in the form of a thick fiufl'y layer, and subjecting the surface of the layer to suction in sufficient degree and' during a period of time adequate to compact the fibrous ingredients of the surface subjected to suction to produce a paperlike skin thereon Without compacting the body of the layer, thereafter subjecting the layer to a lesser degree of suction to extract moisture Without,

compacting the body of the layer, and finally subjecting the layer of material to drying temperature.

5. The method of producing a layer of distended fibrous material, which consists in subjecting a liquid mixture of said fibrous material to a beating action to disintegrate and shorten the fibres to the desired degree, incorporating into the liquid mixture an ingredient adapted under agitation to produce distension due to foaming, agitating the material to produce a distension thereof by the formation of minute bubbles throughout the mass, discharging the material in the form'of a thick-fiuffy layer, and subjecting the surface of the layer to suction in sufficient degree and duringa period of time ade Yuate to compact the fibrous ingredients o the surface subjected to suction to produce a paperlike skin thereon without compacting the body of the layer. A

6. The method of producing a layer of distended fibrous material, which consists in subjecting a liquid mixture of said fibrous material to a beating action to disintegrate and shorten the ,fibres to the desired degree, incorporating into the liquid mixture an ingredient adapted under agitation to produce distension due to foaming, agitating the material to produce a. distension thereof by the formation of minute bubbles throughout the mass, discharging the material in the formof a thick fluffy layer, subjecting the surface of the layer to suction in sufficient degreeand during a period of time adequate to compact the fibrous ingredients of the surface sub jected to suction to produce a paperlike skin thereon without compacting the body of the layer, and thereafter subjecting the layer to dryin operation without compaeting the distende body of the layer.

7. The method of producing a layer of distended fibrous material, which consists in subjecting a liquid mixture of saidfibrous material to a beating action to disintegrate and shorten the fibres to the desired degree,

incorporating into the liquid mixture an inedient adapted under agitation to produce stension due to foaming, agitating the material to produce a distension thereof by the nformation of minute bubbles throughout the mass, discharging the material in the form of a thick fluffy layer, subjecting the surface of the layer to suction in suflicient degree and during a period of time adequate to compact the librous ingredients of the surface sub-A jected to suction to produce a paperlike skin thereon without compacting the body of the la er, and thereafter subjecting the layer to a esser degree of suction to extract moisture Without compacting the body of the layer.

8. The method of producing a layer of distended fibrous material, which consists in subjecting a liquid mixture of said fibrous material to a beating action to disintegrate and shorten the fibres to the desired degree, incorporating into the liquid mixture an ingredient adapted under vagitation to produce distension due to foaming, agitating the material to produce a distension thereof by the formation of minute bubbles throughout the mass, discharging the material in the form of a thick fiuffy layer, subjecting the surface of the layer to suction in sufficient degree and during a period of time adequate to compact the fibrous ingredients of the surface subjected to suction to produce a paperlike skin thereon Without compacting'the body of' the layer, thereafter subjecting the layer to a lesser degree of suction to extract moisture Without compacting the body of the layer, and finally subjecting the layer of material to drying temperature.

9. The method of producing a layer of distended fibrous material, which consists in subjecting a liquid mixture of said fibrous material to a beating action to disintegrate and shorten the vfibres to the desired degree, introducing into the mixture a quantity of long fibred hairlike material adapted to increase the cushioning properties of the completed product, incorporating into the liquid mixturean ingredient adapted under agitation to produce distension due to foaming, agitating the material to produce distension thereof by the formation of minuteA bubbles throughout the mass, discharging the material in the form of a thick fiuy layer, and subjecting the surface of the layer to suction in sufiicient degree and during a period of time adequate to compact the fibrous ingredients of the surface subjected to suction to produce a paper-like skin thereon without compacting the body of the layer.

l0. The method of producing a layer of distended fibrous material, which consists in subjecting a liquid mixture of said fibrous material to a beating action to disintegrate and shorten the yfibres to the desired degree, introducing into the mixture a quantity of long fibred hairlike material adapted to increase the cushioning properties of the completed product, incorporating into the liquid mixture an lngredient adapted under agitan ofby the tion to produce distension due to foaming, agitating the material to produce distension thereof by the formation of minute bubbles throughout the mass, discharging the materia1 iin the form of a thick luy layer, subjecting the surface of the layer to suction in suiiicient degree and during a period of time adequate to compact the fibrous ingredients of the surface su jected to suction to produce a paperlike skin-thereon without compacting the body of the layer, and thereafter subjecting the layer to drying operation without compacting the distended body of the layer.

11. The method of producing a layer of distendedY fibrous material, which consists in subjecting a liquid mixture of said fibrous material to a. beating'action to disintegrate and shorten the fibres to the desired degree, introducing into the a quantity of long ibred hairlike material adapted to increase the cushioning properties of the completed product, incorporating into the liquid mixture an ingredient adapted under agitation to produce distension due to foaming, agitating the material to produce distension thereof by the formation 0fminut/el bubbles throughout the mass, discharging the material in the form of a thick fiufy layer,sub-

`jecting the surface of the layer to suction in suiiicient degree and during a period of time adequate to compact the fibrous ingredients of the surface subjected to suction to produce a paperlike skin thereon without compacting the body of the layer, and thereafter subjecting the layer to a leer degree of suction to extract moisture Without compacting the body of the layer.

12. The method of producing a layer of distended-fibrous material, which consists in subjecting a liquid mixture of said fibrous material to a. beating action to disintegrate and( shorten the fibres to the desired degree, in-

troducing into the mixture a quantity of long fibred hairlike material adapted to increase the cushioning properties of the completed product, incorporating into the liquid mixture an ingredient adapted under agitation to produce distension due to foaming, agitat- `ting the material to produce distension thereformation of minute bubbles throughout the mass, discharging the material in the form of a thick iiuffylayer, subjecting the surface of the layer to suction 1n suicient degree and during a period of time adequate to compact the fibrous ingredients of the surface subjected to suction to produce a paperlike skin thereon without compacting the body of the layer, thereafter subjecting the layer to a lesser degree of suction to extract moisture without compacting the body of the layer, and finally subjecting the layer of material to drying temperature.

li. The method of producing a distended ayer'of fibrous materiai, which consists in Il subjecting the. fibres in with a iiquid layer of of distended libres and having the body Y to a beating action to disintegrate the fibres and reduce them to the desired degree of neness, incorporatin into the semi-liquid mass an ingredient a apted under agitation to produce distension by foaming, agitating the material to cause distension by the formation of bubbles throughout the mass, feeding i the'thick fluffy layer of material to a conltinuously moving surface, momentarily subjecting the surface of the material to a relatively high suction sulicient to cause the formation by compacting of the fibres of a paperlike skin without compacting the body of the layer, continuously moving the layer of material away from the point of suction, subjecting the moving material to a lesser degree of suction to reduce the liquid content without materially compacf ng the distended bodyA of the layer.

14. The methodY of producing a distended layer of fibrous material, which consists in subjecting the fibres in mixture with a liquid to aV beating action to disintegrate the fibres and reduce them to the desireddegree of fineness, incorporating into the semi-liquid mass an ingredient adapted under agitation to produce distension by foaming, agitating the material to cause distension by the formation of bubbles throughout the mas, feeding a thick fluffy layer of material to a continuously momentarily subjecting the high moving surface,

surface of the material to a relativelyv suction suicient to cause the formation, by

libres, of a paperllke without compacting the body of the layer, continuously moving.. the layer of material away from the point of suction, and subjecting the moving material to a leer degree of suction to reduce the liquid content without materially compacting the distended body of the layer, and continuously moving the Juacompacting of the terial through a heated zone to completelyv extract the moisture.

15."The method of producing a distended layer of fibrous material, which consists in incorporating fibres an ingredient adapted under agitation to produce distension by foaming, agitatino' the material to cause diension by' the foimation of bubbles throughout the mass, feeding a thick fluffy layer of material to a continuously moving surface, momentarily subjecting the surface of .the material to a relatively high suction suficientfto cause the formation by compacting of the libres of a paperlike skin Without compacting the body y of the layer, continuously moving the layer of material away from the point of suction, and subjecting the moving material to a lesser degree of suction to reduce the liquid content withoutmaterially compacting the distended body of the layer. n

16. As a new article of manufacture, a material having a cushion-likebody into a liqueed mixture of fibres of one of the surfaces compacted in the form of a thin relatively tough and paperlike skin.

17. As a new article of manufacture, a layer having a body of libres distended by the formation therethrough of bubbles, and having the body fibres of one ofits surfaces compacted in the form of a thin relatively tough and coherent paper-like skin.

18. The method of producing a layer of distended fibrous material which consists in subjecting the material While in semi-liquid condition `to a treatment to cause distension of the mass', discharging the material in the form of a thick Huffy layer, and subjecting the surface of the layerV to suction 1n suiicient degree and during a period of time adequate to compact the fibrous ingredients of the surface subjected to suction to produce a paperlike skin thereon Without compacting the body of the layer. j

19. The method of producing a layer of distended fibrous materialwhich consists in subjecting the material While in semi-liquid condition to a treatment to cause distension of the mass, discharging the material in the form of a thick fluffy layer, and subjecting the surface of the layer to vsuction in Suthcient degree and during a period of time adequate to compact the fibrous ingredients of the surface subjected to suction to produce la paperlike skin thereon Without compacting the body of the layer, and thereafter subjecting the layer to drying operation Without compacting the d-istended body of the layer. t

In Witness that I claim the foregoing l have hereunto subscribed my name this 12th day of June, `1930.

- FRANK L. BRYANT. 

